Description
As a result of multi-material constructions, dissimilar material pairings must be joined in the modern body shop of the automotive industry. Established thermal joining methods, such as resistance spot welding, reach their process limits. On the other hand, mechanical joining techniques used as standard reduce flexibility in the production lines. For this challenge, resistance element welding with upset auxiliary joining elements must be emphasized as a new process-technical approach for joining dissimilar material pairings. This process approach enables the use of conventional resistance spot welding equipment in the body shop for the joining of multi-material pairings. Within the scope of this research, the forming-technical interactions for influencing the joint strength were identified for this innovative process alternative of resistance element welding, and a comprehensive process understanding was developed. The focus of the research was on the analysis of the main influencing factors on joint strength. The resulting cross-process effects to influence the joint strength were combined in a material flow model. The applicability of conventional resistance spot welding was proven and the associated influence of the failure behaviour in the static and dynamic stress cases was discussed. Thus, through this research, a basic process understanding on resistance element welding with upset auxiliary joining elements could be developed, which forms the necessary basis required for a broad industrial application.
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